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Digital Twins by the Numbers

92%

Of enterprises report improved asset performance using Digital Twins for real-time monitoring and diagnostics

3x

faster incident resolution when combining IoT telemetry with simulation and root-cause analytics

68%

reduction in unplanned downtime with predictive maintenance powered by real-time twin models

2x

higher ROI in digital transformation initiatives when Digital Twins are integrated across product, process, and facility layers

Platform Highlights

Enables real-time simulation and monitoring of physical assets by creating virtual replicas that mirror their behavior, performance, and environment

01

Stream sensor and system data into the Digital Twin in real time to reflect current conditions and performance

02

Use AI and physics-based models to simulate behavior, test scenarios, and forecast outcomes

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Sync data from edge devices and send feedback or control signals for responsive automation

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Model complex, interconnected systems using graph-based architectures for enhanced traceability and insight

Core Principles Behind XenonStack’s Digital Twin Approach

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Composable by Design

Build tailored Digital Twin solutions for equipment, processes, or full systems using modular microservices

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AI-Augmented Simulation

Combine real-time data with machine learning and simulation to predict failures, optimize performance, and reduce costs

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Domain-Driven Modeling

Leverage industry-specific templates and ontologies for manufacturing, energy, healthcare, and smart cities

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Security and Interoperability First

Ensure secure, standards-based communication across OT, IT, and cloud ecosystems

Powering Industry 5.0 with IoT, AI, and Immersive Technologies

Empowering IoT-Driven Intelligence

Connect and contextualize real-time sensor data to improve operational efficiency, reduce warranty claims, and lower overall lifecycle costs

Streamlining Operations with Predictive Insight

Boost productivity while reducing downtime and maintenance costs—achieving higher system reliability and safer working conditions

Reimagining Manufacturing with Digital Twins

Enable early mechanical fault detection, dynamic response to changing environments, and reduced risk of system failure through continuous simulation and optimization

Our Digital Twin Development Approach

Domain-Specific Twin Modeling

Create semantic twin models for assets, machines, or systems using contextual ontologies and metadata

IoT & Edge-Native Architecture

Ingest high-frequency data from sensors, PLCs, and SCADA systems with low-latency, edge-ready platforms

AI and Simulation Co-Execution

Run predictive analytics and scenario simulations in parallel to guide real-time decisions

Integrated Visualization and Control Dashboards

Provide teams with intuitive interfaces for interacting with digital replicas, alerts, and diagnostics

Continuous Feedback Loops

Enable learning systems that refine twin behavior based on performance, feedback, and new data

Competencies

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Benefits of Digital Twin Solutions

Offers transformative benefits by creating real-time virtual replicas of physical assets, enabling predictive insights and operational optimization

Visibility Redefined

Gain a live, digital view of systems, processes, and performance in one place

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Efficiency Redefined

Optimize operations with predictive insights, real-time monitoring, and faster decision cycles

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Innovation Redefined

Simulate new processes or designs before deploying in the real world

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Resilience Redefined

improve reliability, reduce downtime, and ensure safety through simulation and automation

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Ready to Build a Digital Replica of Your Operations

Talk to our digital twin architects about building intelligent, real-time models that mirror, monitor, and optimize your most critical systems

Industry 4.0 Digital Twin: Smart Manufacturing

Explore how Digital Twins revolutionize smart manufacturing by enabling predictive maintenance, process optimization, and connected factory operations in Industry 4.0

What is Digital Twin Technology

Understand the fundamentals of Digital Twin technology, its architecture, and how it enables real-time simulation, monitoring, and optimization of physical assets and systems